X-CYCLONE® technology

X-CYCLONE®, REVEN® and REVEX® Technologies

X-CYCLONE® technology protected by international PCT patent rights, based on further improvement of the arrow geometry!

X-CYCLONE® technology was developed for the separation of air-borne substances, such as aerosols, fluid and spraying mists and fine dusts that are released during manufacturing and finishing processes in the food processing and manufacturing industry.Thanks to decades of continuous research and development, we succeeded in presenting the fifth product generation of the X-CYCLONE® air cleaner to the world in 2012.The new air cleaner is characterised by a new arrow geometry and an increase in separating efficiency of 20 %.

The X-CYCLONE® basic element is self-cleaning and needs no maintenance! The aerosols separated in the basic element run down as fluid mass along the X-CYCLONE® profile sections. As it runs off, the liquid washes away solids that accumulate on the profile surfaces of the basic element. Disposable products that must be replaced at regular intervals are not required. Operation and maintenance are therefore far more cost efficient than with conventional air cleaners.

Functional Description of the Separation in the X-CYCLONE®

Separation in the X-CYCLONE® basic aerosol separator element takes place in four stages.

The rotational vortex flows collide with non-rotational airflows at the air outlet of the X-CYCLONE® basic aerosol separator element, thus resulting in an agglomeration and further separation of smaller aerosol particles.

The aerosols separated in the X-CYCLONE® basic aerosol separator element accumulate on the profile surfaces and run down as fluid mass to the bottom of the element.

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Fine dust is separated in the same way. The dust particles do not run down like the fluids, however.

A REVEX® system must therefore be integrated if dry and sticky fine dusts are separated. The REVEX® system is based on a patented spraying technology that fulfils two functions:

(A) It cleans the profile surfaces of the X-CYCLONE® basic aerosol separator element automatically and (B) cleans the air in the same way as an air washer in chemical industry. The continuous air washing by the REVEX® spraying system washes even the smallest aerosols and harmful gases out of the airflow.

CFD Simulation

For years, the X-CYCLONE® and REVEN® systems have been continuously analysed and progressively improved with the help of CFD!

Airflows are complex and cannot be mapped by analytical means. The only way to examine and understand theses flows and gain useful knowledge for the improvement of processes and products is their simulation with computational fluid dynamics (CFD). Even highly complex airflows at the front and back spoilers of modern Formula One racing cars are analysed and optimised by today’s racing teams with the help of CFD simulation. The airflows outside and inside the chassis of a Formula One racing car, an air cleaner or an induction collection hood are decisive for perfect and efficient functioning. CFD simulation maps these important invisible processes in their entire complexity with sound physical and mathematical models. The great benefit in comparison to experimental methods and measurements lies in the fact that CFD maps all physical entities together in their interaction and provides evidence of the functioning instead of delivering values merely for selected points. This is the reason why we have used CFD simulation for years to analyse and improve our equipment. The X-CYCLONE® air-cleaning system and REVEN® induction system were both developed with the help of CFD simulation!

The new advanced induction technology

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Workplace Exposure Limits

Clean air for workers in industry

In food processing as well as machining processes on machine tools, high concentrations of PM10 aerosols are released. PM10 aerosols are airborne particles with a diameter of less than 10 μm. The comparison with a human hair illustrates the difference in size between a five-micrometer particle and a human hair. PM10 particles may occur in very high concentrations in certain processes. An air volume of a thousand cubic metres might contain PM10 concentrations of up to 500 grams.

The WELs for air pollution in the processing industry differ considerably from country to country. The same applies to the verification and control of compliance with these limits. Many studies have revealed in the meantime that even outdoor air pollution in cities has a decisive influence on the health and mortality rate of exposed people. For this reason, Rentschler REVEN bases the design and dimensioning of its equipment on the far more stringent outdoor exposure limits adopted in the metropolises of the world. In many large cities, the maximum permitted concentration of fine dust is 50 micrograms per cubic metre of air. Rentschler REVEN is committed to the following quality goal: the air quality demanded for people in large cities and the limit values that apply there must also be achieved for the industrial workers.

X-CYCLONE® in Compliance with Protective Regulations

Protection of personnel and machines

Scientific research proved that fine dust and airborne aerosols with a droplet diameter of less than 5.0 μm constitute an increased health hazard to exposed personnel. When breathed in, the particles enter the lungs and can cause severe respiratory ailments such as asthma or pulmonary fibrosis. Fine particles are also risk factors for various cancer types. The fine particles do not only enter the body via the respiratory tract, they can also be ingested via the oesophagus or absorbed by the skin.

Possible harm to sensitive plant and machinery, buildings and the environment should not be forgotten either.

Test Stand for Flame Exposure Testing

In connection with manufacturing and finishing processes in mechanical engineering and the food industry, high concentrations of highly inflammable aerosols often have to be extracted and separated. If the aerosols ignite in the exhaust air duct, the flames can spread into the whole building via the duct and set entire building complexes on fire within a few minutes. In order to prevent rapid flame propagation, the flame-arresting capability of all our X-CYCLONE® basic aerosol separator elements is tested in accordance with national and international standards.

REVEN® oil mist separators successfully pass explosion tests

This is why all our X-CYCLONE® basic elements comply with all German, European and North American requirements with regard to their flame-arresting capability. Even their behaviour in explosive environments has been tested and documented.